Belted Compaction Apparatus Kit and Method

ABSTRACT

The present invention relates to a belted compaction apparatus for compacting surfacing materials such as asphalt. In particular, a belted asphalt compactor conversion kit for converting a drum roller compactor into a belted asphalt compactor, the kit comprising a belted compaction apparatus securable to the frame of the compactor, the apparatus comprising a body; a pair of leading rollers at one end of the body and a pair of trailing rollers at the other end of the body; a plurality of intermediate rollers disposed between the leading and trailing rollers; a drive wheel; and a belt wound around the leading, trailing, and intermediate rollers, and the drive wheel, wherein the leading, trailing, and intermediate rollers exert a substantially downward pressure on the bottom nm of the belt to provide a uniform pressure applying surface over the area of the belt in contact with the asphalt.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional application No. 62/351,032 filed Jun. 16, 2016, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present invention relates to belted compaction apparatus for compacting surfacing materials such as asphalt or portland cement concrete.

BACKGROUND

Machines such as compactors are often employed to compact soil, gravel, asphalt, and other materials. Most commonly, these machines include rotating steel drum compactors. A typical steel drum compactor has a drum assembly with one or more drums for compacting the material. The steel drum compactors can be static or dynamic (vibratory or oscillatory). For example, in dynamic steel drum compactors, the drum assembly may include a vibratory mechanism having two or more weights arranged on a shaft rotatable about a common axis within an interior cavity of the drum for inducing vibrations on the drum.

A significant problem which has not been adequately addressed is that of cracking of the asphalt that has been compacted using conventional steel drum rollers. This phenomenon is called “roller checking” and is believed to be caused by the incompatibility of the hard, round steel drum and the soft, flat asphalt pavement. Furthermore, conventional steel drums are round and only a very small area of contact is presented to the asphalt surface for compaction. As the roller travels along the pavement, the asphalt in front of the roller is pushed ahead, causing a pulling force in the asphalt behind the drum. This pushing and pulling action causes the asphalt to crack. Cracks in the pavement are the forerunner of the pothole which forms when water seeps into cracks in a road surface, freezes and expands the pavement. When the ice melts the pavement is shattered by vehicles running thereover.

Another challenge encountered with the use of conventional steel drum rollers is their limited use on bridge decks due to the softness of the underlying waterproofing system and restrictions on the levels of vibration that may be imparted.

Accordingly, there is a need for a system that is flexible, economical, and addresses the deficiencies seen in prior art compactors.

SUMMARY OF THE INVENTION

It is an embodiment of the present invention to provide a belted asphalt compactor conversion kit for converting a drum roller compactor into a belted asphalt compactor, the kit comprising:

-   a belted compaction apparatus securable to the frame of the     compactor, the apparatus comprising:     -   a body;     -   a pair of leading rollers at one end of the body and a pair of         trailing rollers at the other end of the body;     -   a plurality of intermediate rollers disposed between the leading         and trailing rollers;     -   a drive wheel; and     -   a belt wound around the leading, trailing, and intermediate         rollers, and the drive wheel, wherein the leading, trailing, and         intermediate rollers exert a substantially downward pressure on         the bottom run of the belt to provide a uniform pressure         applying surface over the area of the belt in contact with the         asphalt.

According to another aspect there is provided a belted asphalt compactor conversion kit for converting a dual drum roller compactor having a front drum and a rear drum into a belted asphalt compactor, the kit comprising:

-   a leading compaction assembly which replaces the front drum roller     of the drum roller compactor; -   a trailing compaction assembly which replaces the rear drum roller     of the drum roller compactor, wherein each assembly comprises a     plurality of belted compaction apparatus arranged in a side-by-side     configuration, each of said apparatus comprising:     -   a body securable to the frame of the compactor;     -   a pair of leading rollers at one end of the body and a pair of         trailing rollers at the other end of the body;     -   a plurality of intermediate rollers disposed between the leading         and trailing rollers;     -   a drive wheel; and     -   a belt wound around the leading, trailing, and intermediate         rollers, and the drive wheel, wherein the leading, trailing, and         intermediate rollers exert a substantially downward pressure on         the bottom run of the belt to provide a uniform pressure         applying surface over the area of the belt in contact with the         asphalt.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view partial sectional view of a belted asphalt compactor according to an embodiment of the invention;

FIG. 2 is a perspective view of the rear of the compactor showing a trailing compaction assembly comprising two belted compaction apparatus;

FIG. 3 is a rear view of the compactor showing the trailing compaction assembly;

FIG. 4 is a perspective view of the rear of the compactor showing the trailing compaction assembly with the shroud removed;

FIG. 5 is another perspective view of the rear of the compactor showing the trailing compaction assembly with the shroud removed;

FIG. 6 is a perspective view of the compaction assembly according to an embodiment of the invention;

FIG. 7 is another perspective view of the compaction assembly according to FIG. 6;

FIG. 8 is a perspective view of a belted compaction apparatus with the belt removed according to an embodiment of the invention;

FIG. 9 is a rear view of the belted compaction apparatus with the belt removed;

FIG. 10 is an enlarged side view of the belted compaction apparatus installed as part of the trailing compaction assembly on the frame of the conventional compactor;

FIG. 11 is a rear view of the belted compaction apparatus installed as part of the trailing compaction assembly on the frame of a conventional compactor; and

FIG. 12 is a perspective view of the belt for use with the belted compaction apparatus;

FIG. 13 is a perspective view of a compaction assembly according to another embodiment of the invention showing the belt tensioner;

FIG. 14 is a side elevation view of the compaction assembly according to FIG. 6;

FIG. 15 is a side elevation view of a compaction assembly according to another embodiment of the invention

FIG. 16a is side elevation view of a body reinforcing member according to an embodiment of the invention;

FIG. 16b is front view of the body reinforcing member according to FIG. 16a showing the leading rollers;

FIG. 17 is a perspective view of a belted asphalt compactor according to another embodiment of the invention showing weighted members secured to the frame;

FIG. 18 is a front view in partial transparency showing the weighted members according to an embodiment of the invention.

DETAILED DESCRIPTION

Reference will be made below in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals used throughout the drawings refer to the same or like parts.

Referring to the accompanying drawings, there is illustrated a belted compaction apparatus generally indicated by reference numeral 10. Shown in FIG. 1 is a belted asphalt compactor 12 including the belted compaction apparatus 10 for compacting surfacing materials 2, such as asphalt. As will be discussed below, the belted compaction apparatus 10 is particularly suitable for converting a conventional dual drum roller compactor into the belted asphalt compactor 12. In the embodiment shown, the compactor 12 may be derived using any conventional articulated compactor comprising a frame 14.

Compactor 12 comprises a leading compaction assembly 16 forward of an articulation point 18 and a trailing compaction assembly 20 rearward of the point of articulation. Each one of the compaction assemblies 16, 20 comprise two apparatus 10 arranged in a side-by-side relationship spanning substantially the entire width of the compactor 12 as will be described in greater detail below.

As shown in greater detail in FIGS. 2 to 11 and 13, each individual apparatus 10 comprises an elongate body 30 securable to the frame 14 of the compactor 12. In the embodiment shown, the body 30 is in the shape of a triangle, when observed from the side and includes an aperture 32.

In the embodiment shown in FIGS. 5 and 6, the body 30 is securable to the frame 14 by an attachment means 40. The attachment means 40 comprises a cylindrical transverse brace 42 that may extend from one side of the frame 14 to the opposite side of the frame 14 by passing through the aperture 32 in the body 30 and rotatably mounted to bearings 44 which are secured to the frame 14. Attachment means 40 is configured to permit rotation of apparatus 10 about the frame 14 so that the apparatus 10 may be able to better follow any elevation changes in the contour of the surface below. In other embodiments, the attachment means 40 is configured to permit the removable attachment of the body 30 to the frame 14. In some embodiments, the attachment means 40 comprises trailer hitches, fifth wheel couplings, and clamps.

As shown in greater detail in FIGS. 2 to 7 and 12, apparatus 10 further comprises a belt 50. Belt 50 comprises an outer surface 52 which contacts the surface material and an interior surface 54. A plurality of belt retaining members 56 (also known as cogs 56) are provided in interior surface 54 for securing belt 50 to the apparatus 10 as will be described below. The belt 50 may be formed of any suitable material taking into account the specific requirements of any particular application of the compactor. Thus, the belt 50 may comprise resilient material such as laminated rubber which will generally provide a suitable surface texture to the compacted asphalt, for example. In one embodiment, the belt 50 comprises multiple layers and can be a laminated rubber belt having a harder outer layer for contacting the asphalt and a softer inner layer. In another embodiment, the outer and inner layers have a different texture, wherein the outer layer in contact with the surfacing material may have a smooth texture.

A pair of leading rollers 60 is provided at one end of the body 30 and a pair of trailing rollers 62 is provided at the other end of the body 30. As shown in the figures, the leading and trailing rollers 60, 62 are disposed at the base of the body 30.

A plurality of intermediate rollers 70 is disposed between the leading 60 and trailing 62 rollers. As depicted, there are three pairs of intermediate rollers (70 a, 70 b and 7 c), where each of the intermediate rollers 70 has a smaller diameter than the leading rollers 60. As shown in the figures, the intermediate rollers 70 are disposed at the base of the body 30.

Leading 60 and trailing 62 rollers may comprise multiple layers including a solid metal core 64 surrounded by one or more outer layers 66 made of different material than the core. In one embodiment, the core of the leading and trailing rollers is steel and the outer layer is a resilient material.

Similarly, intermediate rollers 70 may comprise multiple layers including a solid metal core 74 surrounded by one or more outer layers 76 made of different material than the core. In one embodiment, the core of the intermediate rollers 70 is steel and the outer layer 76 is a resilient material.

Apparatus 10 further comprises a drive wheel 80 that is rotatably secured at a distance above and separated from the leading 60, trailing 62 and intermediate rollers (70 a, 70 b and 7 c). Drive wheels 80 are powered and each of the drive wheels 80 may be rotated by their own drive motor 81 which can be supported by a motor support 84 secured to the body 30. In an embodiment, the drive wheels 80 are rotated using rotational force generated by one or more hydraulic motors which may be powered by a main engine 22 of the compactor.

Leading 60, trailing 62, and intermediate rollers 70 define a planar bottom run of the belt 52, whereby the bottom run 52 of the belt 50 defines the compaction surface of the apparatus 10. In this manner, the leading 60, trailing 62, and intermediate rollers 70 exert a substantially downward pressure on the bottom run 52 of the belt 50 to provide a uniform pressure applying surface over the area of the belt 50 in contact with the surfacing material 2. Without being limited to any particular theory, the apparatus 10 creates a larger footprint allowing the compaction process to take place over a longer period of time to compress any air out of the compacted surfacing material and provide for better quality compaction of asphalt, for example.

As shown, the belt 50 is wound around the leading 60, trailing 62, and intermediate rollers 70, and the drive wheel 80. Each one of the pair of the leading rollers 60, trailing rollers 62, and intermediate rollers 70 are separated from the other pair by a gap 82. Gap 82 is dimensioned to receive belt retaining members 56 to secure the belt 50 to the apparatus 10 when the belt 50 is wound around the body 30. In some embodiments, when the belt 50 is wound around the rollers and the wheel, and the belt retaining members 56 are inserted into the gap 82, the belt 50 may resist lateral slippage during use where use may include operation on unlevel surfaces such as superelevation.

As will be expected, when the drive wheel 80 is caused to rotate, the belt 50 will turn and will act as an endless track for the leading 60, trailing 62, and intermediate rollers 70 and the compactor 12 will move in a direction desired by the operator.

The compactor 12 may also be equipped with a number of accessories that are advantageous for the compaction process.

The belt 50 may be heat resistant and in some aspects, may be subjected to at least the temperature suitable for compacting freshly laid asphalt, for example about 120° C. to about 150° C. or more before or during the compaction process. In some aspects, the heating of the belt 50 may also ensure that the bitumen on the surface of the asphalt substantially does not adhere to the belt 50. The belt 50 may be heated by any suitable means, for example a super-heated air generator or direct flame heating such as propane flame heating.

A thermal insulating shroud 90 which overlies the belted compaction apparatus 10 or the compaction assemblies 16, 20 may also be provided. Shroud 90 alleviates heat loss from those portions of the belt 50 not in contact with the surface of the asphalt. The shroud 90 may be formed in part or wholly by an insulating shroud and advantageously extends over the belt 50 at least substantially to the level of the compaction surface. Shroud 90 may be formed in one or more parts, for example from reinforced plastics such as fiberglass or a metal such as aluminum or steel with or without insulation.

A scraper bar may be provided to remove excess asphalt fines accumulated on the belt during the surfacing material compaction process. An asphalt fines collection means may also be provided to collect the excess asphalt fines so that the excess asphalt fines are kept away from the compacted surface.

A belt degreasing means and a degreaser reservoir may be provided for degreasing the belt 50 during the surfacing material compaction process.

The compactor may be equipped with a plurality of sensors to monitor speed, direction, and location. Additional sensors measuring temperature of the material to be compacted may also be used. Belt edge sensors may also be provided to detect the lateral position of the edges of the belt so the operator can adjust the direction of the compactor. The compactor may also include a microprocessor to continuously monitor the above-listed parameters to automatically adjust any one of the parameters to provide for better quality of compaction.

One or more belt guides disposed adjacent to the belt may be provided to tension and guide the belt along its intended path, for example. In one embodiment as shown in FIG. 13, the belted compaction apparatus 10 may also comprise a belt tensioner 92 secured to the body 30. Belt tensioner 92 comprises at one end an axle housing 94 configured to rotatably receive the axle of the leading rollers 60 therein and a piston 96 at the other end. As shown, a free end of the piston 96 is secured to the body 30 and actuation of the piston 96 will permit sliding movement of the axle housing 94, and therefore the leading wheels 60, in relation to the body 30. The tension on the belt 50 being adjustable by the movement of the piston 96 because the belt 50 is wound around the leading 60, trailing 62, and intermediate rollers 70, and the drive wheel 80. In some embodiments, the pressures exerted on the belt 50 are about 2000 lbs.

The compactor 12 and apparatus 10 may be configured to suit many different types of applications and environments wherein the dimensions of each of the components can be adjusted for results considered optimal for the particular application. For example, as shown in FIG. 14, apparatus 10 may be configured to have the depicted dimensions which result in an overall weight of 8.90 t or 19621.14 lbs; a surface area of 3797.25 in²; to exert a ground pressure of 5.17 psi or 35.6 kPa.

In another embodiment as shown in FIG. 15, apparatus 10 may be configured to have the depicted dimensions which result in an overall weight of 8.90 t or 19621.14 lbs; a surface area of 3085 in²; to exert a ground pressure of 6.36 psi or 43.8 kPa. It is revealed that in some applications that a ground pressure of at least 6 psi can achieve optimum results.

As shown in FIGS. 16a and 16b , apparatus 10 may further comprise a pair of body reinforcing members 100 which add structural support and rigidity to the body 30.

As shown FIGS. 17 and 18, compactor 12 further comprises weighted members 110 secured to the frame 14. The weighted members 110 are configured to adjust the overall weight of the compactor 12 so that the apparatus 10 (and therefore the compaction assemblies 16, 20) may be able exert an optimal ground pressure for a specific application.

In one embodiment, the method of converting a conventional dual drum roller compactor to the belted asphalt compactor 12 converted comprises the steps of decoupling the drum rollers from the frame of the conventional dual drum roller compactor, and hoisting the frame to facilitate the removal of the drum rollers from underneath the frame. Positioning one or more of the apparatus 10 underneath the frame and lowering the frame onto one or more of the apparatus 10. Securing the apparatus 10 to the frame using an attachment means 40. Wherein the securing comprises inserting a traverse brace 42 into an aperture 32 of the apparatus 10, securing bearings 44 to the frame 14, and then coupling the brace 42 to the bearings 44. Operationally connecting the drive wheel 80 to at least one drive motor 81.

The embodiments of the present application described above are intended to be examples only. Those of skill in the art may effect alterations, modifications and variations to the particular embodiments without departing from the intended scope of the present application. In particular, features from one or more of the above-described embodiments may be selected to create alternate embodiments comprised of a subcombination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternate embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and subcombinations would be readily apparent to persons skilled in the art upon review of the present application as a whole. Any dimensions provided in the drawings are provided for illustrative purposes only and are not intended to be limiting on the scope of the invention. The subject matter described herein and in the recited claims intends to cover and embrace all suitable changes in technology. 

1. A belted asphalt compactor conversion kit for converting a drum roller compactor into a belted asphalt compactor, the kit comprising: a belted compaction apparatus securable to the frame of the compactor, the apparatus comprising: a body; a pair of leading rollers at one end of the body and a pair of trailing rollers at the other end of the body; a plurality of intermediate rollers disposed between the leading and trailing rollers; a drive wheel; and a belt wound around the leading, trailing, and intermediate rollers, and the drive wheel, wherein the leading, trailing, and intermediate rollers exert a substantially downward pressure on the bottom run of the belt to provide a uniform pressure applying surface over the area of the belt in contact with the asphalt.
 2. The kit of claim 1 wherein the apparatus is securable to the frame by an attachment means.
 3. The kit of claim 2 wherein the attachment means comprises a transverse brace that extends from one side of the frame to the opposite side of the frame by passing through an aperture in the body.
 4. The kit of claim 2 wherein the attachment means is a reversible attachment means.
 5. The kit of claim 4 wherein the reversible attachment means is a hitch or a coupling.
 6. The kit of claim 1 wherein one or all of the leading, trailing, and the intermediate rollers comprise a core surrounded by an outer layer, the outer layer comprising a resilient material.
 7. The kit of claim 6 wherein the resilient material is rubber.
 8. The kit of claim 1 wherein the belt is an elastomeric belt.
 9. The kit of claim 8 wherein the elastomeric belt comprises laminated rubber.
 10. The kit of claim 1 wherein the body is triangular and the leading, trailing and intermediate rollers are rotatably secured to the base and the drive wheel is rotatably secured at a distance above the leading, trailing and intermediate rollers.
 11. A belted asphalt compactor conversion kit for converting a dual drum roller compactor having a front drum and a rear drum into a belted asphalt compactor, the kit comprising: a leading compaction assembly which replaces the front drum roller of the drum roller compactor; a trailing compaction assembly which replaces the rear drum roller of the drum roller compactor, wherein each assembly comprises a plurality of belted compaction apparatus arranged in a side-by-side configuration, each of said apparatus comprising: a body securable to the frame of the compactor; a pair of leading rollers at one end of the body and a pair of trailing rollers at the other end of the body; a plurality of intermediate rollers disposed between the leading and trailing rollers; a drive wheel; and a belt wound around the leading, trailing, and intermediate rollers, and the drive wheel, wherein the leading, trailing, and intermediate rollers exert a substantially downward pressure on the bottom run of the belt to provide a uniform pressure applying surface over the area of the belt in contact with the asphalt.
 12. The kit of claim 11, wherein each assembly comprises two apparatus. 